Yamaha 760 Locked Up

Hi all, first post, could have been on better terms... Purchased a GP760 for dirt that had decent compression (130 in the front and around 125 in the rear). Went through a carb rebuild, cleaned the fuel tank out. It ran great for a few weeks. Had it's first hiccup in Homasassa on the 4th, it was running great then just died, waited a bit and it would start up, run for about 30 seconds and died. gat a tow back to the dock and pulled it. Got it back to Orlando, started up fine on the hose and ran fore a few minutes no problems. Took it out this past weekend to keep some time on it for a cruise around the lake and all was good until it started doing the same thing after about 30 minutes of just cruising around. Waited a bit and it fired back up and i headed back to the dock, about 30 seconds later it died again, but no sputter, just death, and hard stop. No noise when I hit the start switch. Got a tow in, pulled it, popped the plugs off, back hole was tan/brown, front hole completely black (Plugs were changed after homasassa). Pulled the coupling cover off and with the plugs out, she was locked up solid. Started pulling the motor right away, got it out and on the bench and found immediately that the flywheel housing on the case is cracked???? Pulled down the cylinders, and the back rod had seized. Something got hot. I'm trying to work my way to diagnose the issue further The water jacket on the back cylinder is about 35% full of small shells, not helping things. The carbs are set to run pretty rich with a 40-1 mix, I'm pretty sure it is responsible for the death of a few polar bears.

I've attached some pics, I wanted to get some opinions from someone who is smarter than me as to whether the case can be saved/welded. Also any potential leads to shake down and find the culprit to this engines demise. It could very well be that this engine had never seen the light of day since it was assembled as the ski only has 168 hours on it, and it's a 1997. So I'm throwing about 60% into age. I do not know how long it sat before I bought it, as it came by way of a third party. So it's possible it sat for a year or seven, as I had to do a fair amount of glasswork to the keel and 2x4 trailer bunk size hole in the upper hull.

Anyways, sorry for novel, and thanks in advance!

-Ryan




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If I'm not mistaken all 650/701/760 used the same lower case half. Is yours stamped 6m6? If so, I would just replace the lower half. That crack looks pretty bad, and there are plenty of used lower case half out there in good condition. Did the top case half survive all the Carnage?


I'm not a resident guru here but if I had to guess the case crack caused an air leak, shells in water jackets werent helping, went lean and just got too hot and the oil film burned off the piston which caused the first unexpected shut off. Piston wash on the one piston all sooty and lean. What do the reeds look like out of curiousity? The age of the motor/low compression was a factor, I agree with you there.

Whenever the ski "just stops" while you're crusing down the lake, then starts back up and seems sort of ok... it's very possible a piston has experienced scoring/seizing, and that top end is usually toast and it's not good to continue running it trying to diagnose any ancillary problems. If the ski shuts off like that, look into the spark plug holes or pull exhaust manifold and look in there with inspection camera to see if you can find damage to the bore or pistons.

Periodic engine case pressure testing is a good idea as part of your long term maintenance depending on how you ride.
 
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If I'm not mistaken all 650/701/760 used the same lower case half. Is yours stamped 6m6? If so, I would just replace the lower half. That crack looks pretty bad, and there are plenty of used lower case half out there in good condition. Did the top case half survive all the Carnage?


I'm not a resident guru here but if I had to guess the case crack caused an air leak, shells in water jackets werent helping, went lean and just got too hot and the oil film burned off the piston which caused the first unexpected shut off. Piston wash on the one piston all sooty and lean. What do the reeds look like out of curiousity? The age of the motor/low compression was a factor, I agree with you there.

Whenever the ski "just stops" while you're crusing down the lake, then starts back up and seems sort of ok... it's very possible a piston has experienced scoring/seizing, and that top end is usually toast and it's not good to continue running it trying to diagnose any ancillary problems. If the ski shuts off like that, look into the spark plug holes or pull exhaust manifold and look in there with inspection camera to see if you can find damage to the bore or pistons.

Periodic engine case pressure testing is a good idea as part of your long term maintenance depending on how you ride.


I think for simplicity sake, the condition of the current engine warrants a purchase of a re-man from SBT. They are right down the road from me.

I've been trying to price out individual pieces to replace what needs to be replaced, accounting for unknowns, and the cost are getting close to what it's going to cost for the re-man 760.

The crack in the flywheel housing is still somewhat baffling to me, we cant quite figure this out. This should be a non pressurized area of the case, sealed only against water intrusion. The only conclusion we can come to is that this motor was hurt some time prior, and there may have been a lot of abuse on it in its prior life.

There is no scoring on the top end, it just seems that it sat too long and condensation, or water intrusion happened at some point to cause just enough corrosion. It got hot, but I cant imagine that it got lean. The coloration on the plug looks good on the hole in question. I have been heavy on the oil pre-mix too.

As of right now, everything is bagged and oiled, so if I do decide to go through a re-build I can. But I'm not holding my breath on it.
 
That's true the crack was seemingly out of the pressurized areas of the case, but if your front seal wasnt perfect you would still have a leak. It's not unheard of for a f.w. cover gasket to hide a front seal leak on a otherwise solid engine.

From what I saw in your photos there is some scoring on the bore and piston. Although it's not as bad as I would have expected based on the shutting off symptoms
 
That's true the crack was seemingly out of the pressurized areas of the case, but if your front seal wasnt perfect you would still have a leak. It's not unheard of for a f.w. cover gasket to hide a front seal leak on a otherwise solid engine.
I agree, interesting none the less.
 
You might be right it wasn't super lean, the one piston just looks a little more sooty than the other. Heat destroys these motors real fast, I have burned up several top ends from running race gas lol.

That crack may have been caused by a f.w. or Bendix disaster at some point.
 
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You might be right it wasn't super lean, the one piston just looks a little more sooty than the other. Heat destroys these motors real fast, I have burned up several top ends from running race gas lol.

That crack may have been caused by a f.w. or Bendix disaster at some point.
There were a few small metallic bits on the magnets on the flywheel. I'm guessing that may have been the cause, Bendix disaster, as the current one looks relatively new and not aged too much. The flywheel also looks as though it is in excellent condition.

Something went mildly ballistic inside that housing, and someone completed a "half repair" at some point.

Since this ski is going to be used mainly over on the river in homasassa, I'm not looking for it to be the fastest thing in the world, just make it back forth between the house and the springs.

Even with the reman purchase I will still have less in it than a comparable condition gp760.

I love these older 2 stroke skis, but wifey wants a cruiser. In the off season we are going to be in the market for a newer FX.
 
Yeah you can't deny the simple and effective 2 stroke, some of the Yamaha 4 strokes are incredibly complex (in comparison), ex: the superchargered fz sho engine. The TR:1 seems pretty straightforward and works great in kommander ind builds.
 
Yeah you can't deny the simple and effective 2 stroke, some of the Yamaha 4 strokes are incredibly complex (in comparison), ex: the superchargered fz sho engine. The TR:1 seems pretty straightforward and works great in kommander ind builds.
Yeah, 4 stroke is not my realm. Have a lot to learn in that regard.
 
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